B.Tech.

Project
on

Damping in blisk using split rings

Submitted by: Ishan Jain (2020ME10938)

Supervised by: Dr. Arpan Gupta
Signature of supervisor:

Department of Mechanical Engineering

Indian Institute of Technology Delhi

April, 2024
Acknowledgements

I would like to thank my thesis supervisor, Prof. Arpan Gupta, for his unwavering
guidance and support that proved indispensable throughout the research process. His
wealth of expertise, insightful comments, and constructive criticism played a pivotal role
in shaping the trajectory of this thesis.
In addition, I am grateful to Prof. Ashish K Darpe for his consistent support and
guidance, providing invaluable and profound insights into real-life situations that enriched
the depth of my research.
Furthermore, I extend heartfelt thanks to all those who stood by me during this
challenging yet ultimately rewarding journey. My family and friends have been a pillar
of unwavering support, offering encouragement that fueled my determination. Their
collective belief in my capabilities has been a source of strength, making this academic
endeavour a truly collaborative and fulfilling experience.

i
Abstract

The project aimed to examine the vibrational characteristics of blisks (bladed disks)
and an in-depth analysis of the effectiveness of split rings in mitigating these vibrations.
The vibrational behaviour of blisks was to be examined, with a specific focus on the
damping influence of split rings. The simulation results, critical for assessing dynamic
responses, were validated through a comparison with existing research data, thereby
enhancing the reliability of the findings. The integration of split rings emerged as a
pivotal factor, significantly reducing vibrations within blisks. Furthermore, the research
advanced the understanding of blisk dynamics and validated the simulated outcomes
against prior experimental data, reinforcing the study’s credibility. Using pre-existing
research data for validation purposes emphasizes the project’s commitment to ensuring
accuracy and aligning findings with established knowledge in the field. These insights lay
the groundwork for future research, providing a foundation for stress analysis and physical
experimentation, thereby further enhancing the practical applicability of understanding
blisk behaviour in real-world applications.

ii
Contents

Acknowledgements i

Abstract ii

List of Figures iv

List of Tables v

1 Introduction 1
1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Problem Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Literature Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.1 Under platform dampers . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.2 Hard coating on blades . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3.3 Friction ring dampers . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Research Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Mode Shape analysis of blisk 6

2.1 Vibrations in a simple blisk . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Analysis of a 3D blisk geometry . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.1 Initial Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Eigenfrequency Analysis 11
3.1 Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Simulation Observations . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.1 Effect of Material Damping . . . . . . . . . . . . . . . . . . . . . 12
3.2.2 Effect of Stress Stiffening . . . . . . . . . . . . . . . . . . . . . . . 12
3.2.3 Effect of Spin Softening . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.4 Effect of rotational speed . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.5 Effect of Friction Damper Ring . . . . . . . . . . . . . . . . . . . 14
3.3 Changes in stress due to incorporation of friction ring damper . . . . . . 14

4 Conclusions 16
4.1 Concluding remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Future scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

References 17

iii
List of Figures

1.1 A CNC-milled, single-piece axial compressor blisk [2] . . . . . . . . . . . 1

1.2 (a) CAD model of a turbine-bladed disk with under platform dampers
(b) Sketch representing a close-up of three blades with interposed under
platform dampers [3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Types of under platform dampers: (a) cottage-roof dampers, (b) split
dampers [4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Sample blisk with NiCrAlY coating on blades . . . . . . . . . . . . . . . 3
1.5 Schematic view of blisks and ring damper [9] . . . . . . . . . . . . . . . . 4

2.1 A simple blisk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2 Natural frequencies obtained by analytical method and FEM . . . . . . . 8
2.3 Modal shapes obtained by FEM . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Reference blisk used for analysis . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Comparison of results with different types of blades (Vibrational charac-
teristics at lowest eigenfrequency of respective structure) . . . . . . . . . 9

3.1 3D CAD of simplified blisk used for analysis . . . . . . . . . . . . . . . . 11

3.2 3D CAD of simplified friction damper ring used for analysis . . . . . . . 11
3.3 Campbell diagram for the six lowest modes . . . . . . . . . . . . . . . . . 14
3.4 Stresses in the blisk due to application of external force on one of the blades 15
3.5 Stresses in the blisk reinforced with friction ring damper due to application
of external force on one of the blades . . . . . . . . . . . . . . . . . . . . 15

iv
List of Tables

2.1 Material parameters of the blisk . . . . . . . . . . . . . . . . . . . . . . . 7

2.2 Natural frequencies (Hz) obtained by analytical method and FEM . . . . 7

3.1 Effect on natural frequencies due to material damping . . . . . . . . . . . 12

3.2 Effect on natural frequencies due to stress stiffening induced due to rigid
body rotation (centrifugal forces) . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Effect on natural frequencies due to spin softening . . . . . . . . . . . . . 13
3.4 Effect on natural frequencies due to the inclusion of friction damper ring
underneath the blisk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

v
Chapter 1

Introduction

1.1 Background
A blisk (short for bladed disk) is a turbomachine component that includes both the rotor
disk and the blades, Figure 1.1. It is a critical component of the engine compressor that
allows enough compressed air to enter the engine for combustion to occur. Blisks have
better aerodynamics and are lighter than conventional rotors with single blades. Instead
of a disk assembled with individual removable blades, each blisk is made up of a single
part. They can be additively manufactured, integrally cast, machined from a solid piece
of material, or welded to a rotor disk. The term is mostly used in aerospace engine design.
Integrally bladed rotors (IBR) are another name for blisks [1].

Figure 1.1: A CNC-milled, single-piece axial compressor blisk [2]

Blisk manufacturing has been used since the mid-1980s. Instead of making bare
compressor disks and attaching the blades later, blisks are single elements combining
the two. This eliminates the need to attach the blades to the disk (via screws, bolts,
etc.), thus decreasing the number of components in the compressor while at the same
time decreasing drag and increasing the efficiency of air compression in the engine. The
elimination of the dovetail attachment found on traditional turbine blades eliminates a
source for crack initiation and subsequent propagation. Any damage to integrally bladed
rotor blades beyond minor dents necessitates engine removal in order for the rotor to be
replaced or, if possible, replacement blades to be welded on. This type of maintenance
cannot be performed on the flight line and must frequently be performed at a specialized
facility.

1
CHAPTER 1. INTRODUCTION 2

1.2 Problem Definition

There are numerous benefits to using blisk (integrally bladed rotors) instead of tradi-
tional bladed disk assemblies, especially in terms of aerodynamic performance and mass
reduction. However, unlike assembled components, these single-piece-made structures
lack joints and friction interfaces such as blade roots, shrouds, underplatform dampers,
and so on, and their internal damping is thus very low. As a result, in harsh operating
conditions, blisks can experience high vibration levels and resonances, leading to high
cycle fatigue phenomena and, in the worst-case scenario, failure. This motivates the de-
velopment of new vibration control devices in particular. One such device is split ring,
which is the main focus of this project.

1.3 Literature Survey

The complete avoidance of all resonance regimes is not generally possible due to the
high density of natural frequencies of realistic bladed disks and the broad spectrum of
aerodynamic excitation forces. As a result, the use of special devices that dissipate
vibration energy and, as a result, reduce resonance amplitudes to acceptable levels is
usually required. Various methods have been proposed for dampening the vibrations in
the blisk. Some of them include the use of under-platform dampers (UPD), the use of
friction rings, and hard coating on the blades of the blisk.

1.3.1 Under platform dampers

The underplatform friction damper (UPD), as shown in Figure 1.2, is one of the most
effective types of damping device. It is typically a small piece of metal with a wedge-like
or other shape that is located beneath the blade platforms. Friction forces acting at the
contact interfaces between blades and dampers dampen blade vibration. When blade
displacements reach a certain level, vibration energy is converted into thermal energy.

Figure 1.2: (a) CAD model of a turbine-bladed disk with under platform dampers
(b) Sketch representing a close-up of three blades with interposed under platform
dampers [3]

There is a variety of underplatform damper designs used by different companies for

different types of practical bladed disks, including cottage roof dampers, Figure 1.3(a)
CHAPTER 1. INTRODUCTION 3

and split dampers, Figure 1.3(b), and others [4]. The most commonly used massless
damper models are kinematic damper motion models. In most such models, the relative
motion of the damper along the normal-to-the-damper contact surface is assumed to be
negligible despite the fact that there are conditions under which such motion is significant
and can even lead to damper and blade platform separation.

Figure 1.3: Types of under platform dampers: (a) cottage-roof dampers, (b) split
dampers [4]

1.3.2 Hard coating on blades

Hard coatings, as shown in Figure 1.4, such as thermal barrier coatings and anti-corrosive
coatings, are used as surface treatments to give the composite structure special and
superior performance. In recent years, hard coating has been used as a damping treatment
for vibration reduction in titanium plates as a blade simplification for its better stability
than the viscoelastic damping layer or constrained damping layer in harsh environments.
Another significant advantage of the damping hard coating is that it reduces resonant
peaks without significantly altering structural mass or stiffness due to its thin thickness
[5].

Figure 1.4: Sample blisk with NiCrAlY coating on blades

1.3.3 Friction ring dampers

This method entails inserting small circular rings beneath the blisks wheel. Due to
centrifugal loads, these are held in contact with the blisk, and friction dissipation can
CHAPTER 1. INTRODUCTION 4

occur when some relative motions between the rings and the blisk occur [6]. These
rings are located in dedicated grooves beneath the wheels, and contact is maintained
indefinitely by centrifugal force caused by engine rotation; friction and slipping occur
during the differential motion of the two bodies in contact [7, 8].

Figure 1.5: Schematic view of blisks and ring damper [9]

1.4 Research Gap

The research gap in optimal methods for vibration-damping of blisks using split ring
technology underscores a crucial area that demands more comprehensive exploration.
Despite the extensive literature on vibration-damping techniques, a dedicated and in-
depth investigation into the specific application of split rings still needs to be developed.
Split rings present a promising avenue for effective vibration mitigation. However, their
potential still needs to be explored due to a need for more studies elucidating the intricate
details of their implementation.
Questions surrounding the optimal design parameters, strategic placement on blisk
structures, and the nuanced influence on dynamic behaviour have yet to be sufficiently
addressed [10]. A robust understanding of these factors is imperative for developing
tailored solutions that harness the full potential of split ring technology in blisk vibration
control.

1.5 Objectives
This project’s primary goal is to comprehensively examine the frequency response and
vibratory stresses within the blisk (bladed disk) structure. The analysis will delve into
the frequency response of the blisk, which refers to how the structure responds to different
excitation frequencies. This investigation is vital for identifying resonant frequencies and
potential vibration modes that can lead to structural issues or reduced performance.
An additional aspect of the research involves investigating the effectiveness of the split
ring method in damping vibrations and its impact on stress levels. This involves assessing
CHAPTER 1. INTRODUCTION 5

whether the introduced damping mechanisms effectively reduce vibration amplitudes and
how these changes affect the overall structural integrity. The project has the following
broad objectives:

1. Undertake a computational analysis to model and determine eigenvalues for a com-

pact blisk configuration.

2. Perform a computational assessment of vibratory stresses on the blisk, considering

both cases—with and without using split ring dampers.
Chapter 2

Mode Shape analysis of blisk

2.1 Vibrations in a simple blisk

We started with a simple blisk design to understand the patterns of natural frequencies
and mode shapes of such type of structures. We took sample dimensions from work of
Yugang Chen et al. [5] and constructed the 3D CAD model as shown in Figure 2.1, with
width of 2 mm. The material properties used for this blisk are given in Table 2.1 [5].
The structure under consideration in this study is an academic blisk characterized by
16 sectors crafted from stainless steel using wire-electrode cutting. This manufacturing
process ensures the cyclic symmetry property of the blisk, a crucial aspect for its structural
integrity and performance analysis.
45

20

15
R1

91

SOLIDWORKS Educational Product. For Instructional Use Only.

(a) Dimensions (b) 3D rendering

SOLIDWORKS Educational Product. For Instructional Use Only.

Figure 2.1: A simple blisk

Natural frequencies of the blisk obtained by the analytical method [5] are listed in Ta-
ble 2.2. Also, a finite element model was established in COMSOL Multiphysics software.
Figure 2.2 illustrates the comparison of natural frequencies obtained through analytical
methods and Finite Element Method (FEM). Notably, there is a discernible consistency
among these results. Furthermore, it is observed that, particularly in higher-order modes,
the analytical method yields results closer to the experimental findings. The accuracy
of FEM results is influenced by factors such as meshing size, meshing shape, element
type, and attributes. In this study, the accuracy of FEM results for higher-order modes

6
CHAPTER 2. MODE SHAPE ANALYSIS OF BLISK 7

Property Value
Elastic modulus 210 GPa
Mass density 7900 kg/m3
Poisson’s ratio 0.3
Loss factor 0.0017

Table 2.1: Material parameters of the blisk

is found to be less satisfactory. To enhance accuracy, the use of higher-order elements

and a finer mesh may be necessary in FEM analyses.

Mode order Analytical method FEM - COMSOL

1-1 174.16 173.72
2-1 194.19 194.51
3-1 255.22 259.81
4-1 323.74 346.69
5-1 392.96 420.24
6-1 434.86 469.34
1-2 713.02 789.65
2-2 751.93 835.99
3-2 845.23 937.42
4-2 1053.11 1113.90
5-2 1260.97 1366.90
6-2 1552.93 1673.20

Table 2.2: Natural frequencies (Hz) obtained by analytical method and FEM

The outcomes of the analytical method encompass the modal shapes of both the
disk and a representative blade. These results unveil that strong-coupled vibrations
predominantly characterize the mode types in blisk vibrations. Specifically, in the second
mode with n = 3, a nodal circle manifests on the blades spaced circumferentially, with
one nodal point on each blade. This pattern resembles the mode type observed in a
single disk, although in this case, the location of the nodal circle spans the entirety of the
blades. Additional modal shapes obtained through modal testing are detailed in Figure
2.3.
CHAPTER 2. MODE SHAPE ANALYSIS OF BLISK 8

1800
Analytical method
1600 FEM - COMSOL

1400

1200
Frequency (Hz)
1000

800

600

400

200

0
0 2 4 6 8 10 12
Mode order

Figure 2.2: Natural frequencies obtained by analytical method and FEM

(1, 1) (2, 1) (3, 1)

(4, 1) (5, 1) (6, 1)

(1, 2) (2, 2) (3, 2)

(4, 2) (5, 2) (6, 2)

Figure 2.3: Modal shapes obtained by FEM

CHAPTER 2. MODE SHAPE ANALYSIS OF BLISK 9

2.2 Analysis of a 3D blisk geometry

After analysing a simple 2D blisk geometry, we analysed a 3D blisk structure, which was
very much similar to an actual blisk used in turbomachinery, as shown in Figure 2.4. We
got the 3D CAD from [11].

SOLIDWORKS Educational Product. For Instructional Use Only.

Figure 2.4: Reference blisk used for analysis

2.2.1 Initial Analysis

Upon importing the CAD model into COMSOL and conducting an initial analysis, it
became evident that the model faced certain issues, resulting in outcomes that needed to
align with our expectations. Upon closer examination during post-analysis, we identified
a crucial factor contributing to this discrepancy: the blades in the CAD were initially
configured as 2D film-type structures devoid of vibrational tendencies.

(a) With 2D blades (b) With 3D blades

Figure 2.5: Comparison of results with different types of blades (Vibrational

characteristics at lowest eigenfrequency of respective structure)
CHAPTER 2. MODE SHAPE ANALYSIS OF BLISK 10

A decision was made to edit the CAD model. The crucial modification involved
introducing a certain thickness to the blades, transforming them from flat, 2D structures
into three-dimensional entities. This alteration aimed to impart vibrational tendencies to
the fins, a characteristic lacking in the initial design. Following these CAD adjustments,
we proceeded to re-run the simulations in COMSOL. This subsequent analysis showed
notable improvements compared to the initial results, as shown in Figure 2.5. It can be
seen that after introducing thickness to the blades, they also show a vibrational nature.
Adding thickness to the blades proved to be a pivotal step in enhancing the model’s
overall performance and aligning it more closely with our expectations.
Chapter 3

Eigenfrequency Analysis

3.1 Methodology
For the present analysis a simplified model of the blisk with 20 flat blades is considered,
as shown in Figure 3.1. The 3D CAD of the model was designed in SolidWorks and then
imported in COMSOL Multiphysics for further analysis. For the current study, material
of the disc was assigned as Structural Steel, which is one of the material available in the
inbuilt material library of COMSOL.

Figure 3.1: 3D CAD of simplified blisk used for analysis

SOLIDWORKS Educational Product. For Instructional Use Only.

Similarly, a friction damper ring was designed for the analysis, as shown in Figure
3.2. The same Structural Steel material is also assigned to the ring for this simulation.

Figure 3.2: 3D CAD of simplified friction damper ring used for analysis
SOLIDWORKS Educational Product. For Instructional Use Only.

11
CHAPTER 3. EIGENFREQUENCY ANALYSIS 12

3.2 Simulation Observations

After setting up the environment in COMSOL, eigenfrequency analysis was done by
varying various factors.

3.2.1 Effect of Material Damping

The case in which the effect of damping has a prominent role is when a structure is
subjected to a harmonic excitation at a frequency that is close to a natural frequency.
Exactly at resonance, the vibration amplitude tends to infinity, unless there is some
damping in the system. Here the isotropic loss type damping is used in the simulations
[12]. The isotropic loss factor damping is described by the single isotropic loss factor
ηs , which acts on all entries in the elastic constitutive matrix. It’s value for the given
material was preset in the material library.

Mode Without damping With damping

1 397.48 397.49
2 436.24 436.25
3 525.94 525.97
4 810.29 810.33
5 1,396.86 1,396.93
6 1,968.68 1,968.78
7 2,463.83 2,463.95
8 2,477.81 2,477.94
9 2,581.25 2,581.38

Table 3.1: Effect on natural frequencies due to material damping

As can be seen from Table 3.1, natural frequencies increase as a result of considering
the material damping effect.

3.2.2 Effect of Stress Stiffening

Due to rotation, centrifugal force act throughout the volume of the body resulting in
stress generation. The stress-stiffening effect, or geometric stiffening, is a phenomenon
affecting the dynamics of stressed structures: the stresses acting on the structure intro-
duce localised additional stiffnesses which change the natural frequencies of the structure.
To include the stress-stiffening effects in the model, we need to activate the large defor-
mation option. This redefines the strain measure to include second-order terms, which
makes the strain-displacement relation nonlinear. The resulting strain measure is called
Green strain.
CHAPTER 3. EIGENFREQUENCY ANALYSIS 13

Mode Without stress stiffening With stress stiffening

1 397.48 481.00
2 436.24 501.75
3 525.94 578.06
4 810.29 865.38
5 1,396.86 1,437.73
6 1,968.68 2,003.88
7 2,463.83 2,495.96
8 2,477.81 2,547.14
9 2,581.25 2,623.52

Table 3.2: Effect on natural frequencies due to stress stiffening induced due to rigid
body rotation (centrifugal forces)

As can be seen from the Table 3.2, there is considerable increase in the natural fre-
quencies due to stress stiffening.

3.2.3 Effect of Spin Softening

Any radial displacement away from the axis of rotation increases the centrifugal force,
while motion toward the axis decreases it. This effect therefore tends to amplify any radial
motion, which is the opposite of stiffening, hence spin-softening. The spin-softening effect
ultimately arise because the standard form of the laws governing the deformation of solid
objects only hold in inertial, that is, non accelerating, coordinate systems.

Mode Without spin softening With spin softening

1 481.00 479.90
2 501.75 501.25
3 578.06 577.80
4 865.38 864.28
5 1,437.73 1,436.73
6 2,003.88 2,002.95
7 2,495.96 2,495.12
8 2,547.14 2,545.83
9 2,623.52 2,618.23

Table 3.3: Effect on natural frequencies due to spin softening

As can be seen from the Table 3.3, there is decrease in the natural frequencies due to
spin softening.

3.2.4 Effect of rotational speed

To understand the concept of how natural frequency will depend on the angular speed of
the rotor, we plot the variation of the natural frequency for different modes against the
angular speed of the rotor, which is often called a Campbell diagram.
CHAPTER 3. EIGENFREQUENCY ANALYSIS 14

Figure 3.3: Campbell diagram for the six lowest modes

3.2.5 Effect of Friction Damper Ring

Mode Without friction damper With friction damper

1 397.48 396.03
2 436.24 435.04
3 525.94 524.39
4 810.29 806.68
5 1,396.86 1,389.99

Table 3.4: Effect on natural frequencies due to the inclusion of friction damper ring
underneath the blisk

As can be seen from Table 3.4, natural frequencies decreased due to incorporation of
friction ring damper inside the groove present underneath the rim of the blisk.

3.3 Changes in stress due to incorporation of friction

ring damper
Now, an external force of 100N was applied on the outer surface of one of the blades of
the blisk and the stress generated was analysed. As can be seen from the Figure 3.4 and
Figure 3.5, there was a decrease in the maximum stress generated in the blisk after the
usage of friction ring damper. Although it is a case of static loading, but the effect could
be extrapolated to the case of dynamic loading.
CHAPTER 3. EIGENFREQUENCY ANALYSIS 15

Figure 3.4: Stresses in the blisk due to application of external force on one of the blades

Figure 3.5: Stresses in the blisk reinforced with friction ring damper due to application
of external force on one of the blades
Chapter 4

Conclusions

4.1 Concluding remarks

In conclusion, this report has presented a comprehensive study on vibrations and damping
mechanisms in a blisk (bladed disk). The investigation involved a detailed analysis of the
blisk’s vibrational behaviour, focusing on mitigating undesirable vibrations through the
implementation of damping techniques. The use of split rings as a damping mechanism
was explored in detail. The simulations provided valuable insights into the effectiveness
of split rings in reducing vibrations within the blisk.
In essence, this study underscores the importance of a thorough investigation into vi-
bration phenomena and the implementation of effective damping strategies. The knowl-
edge gained from this study has practical implications for engineering applications, pro-
viding a foundation for further research and development in the quest for more robust
and resilient rotating machinery systems.

4.2 Future scope

The future endeavours will encompass stress analysis and physical experimentation. The
upcoming stress analysis aims to delve into the mechanical stresses experienced by the
blisk during operation. This critical examination will involve simulations and computa-
tions to assess the material resilience and structural response under various operational
conditions. By identifying stress concentrations and potential failure points, we aim to
enhance the durability and reliability of the blisk in real-world applications. Additionally,
our commitment to experimental validation will involve physical testing to corroborate
and refine the findings from the simulations. This research phase will include laboratory
experiments designed to measure and validate the vibrational and stress characteristics
observed in the simulated models.

16
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